Methods of manufacturing jaw members of surgical forceps

ABSTRACT

A method of manufacturing a jaw member of a surgical forceps includes forming a jaw frame having a distal jaw support. The method also includes forming an electrically-conductive defining an aperture having a first diameter, forming a stop member including a body having a second diameter smaller than the first diameter and a shoulder having a third diameter greater than the first diameter. The method also includes inserting the stop member into the aperture such that the body extends through the aperture and the shoulder abuts a portion of the electrically-conductive plate surrounding the aperture, and overmolding an outer housing about at least a portion of the jaw frame, electrically-conductive plate, and stop member to secure the jaw frame, electrically-conductive plate, and stop member to one another.

BACKGROUND

Technical Field

The present disclosure relates to surgical instruments and methods and,more particularly, to surgical forceps and methods for manufacturing jawmembers of surgical forceps.

Background of Related Art

Open or endoscopic electrosurgical forceps utilize both mechanicalclamping action and electrical energy to effect hemostasis. Theelectrode of each opposing jaw member is charged to a different electricpotential such that when the jaw members grasp tissue, electrical energycan be selectively transferred through the tissue. A surgeon can treattissue by either cauterizing, coagulating/desiccating, sealing, and/orsimply reducing or slowing bleeding, by controlling the intensity,frequency and duration of the electrosurgical energy applied between theelectrodes and through the tissue.

In order to promote accurate, consistent and effective, sealing andother tissue treatment effects, one or more insulative stop members maybe positioned along one or both opposed surfaces of the jaw members tomaintain a specific gap distance between the jaw members when the jawmembers are in a clamping position with tissue grasped therebetween.

The stop members may be secured to the opposed surfaces of the jawmembers via one or more suitable securement methods. The currenttechniques of forming and securing the stop members to the opposedsurfaces of the jaw members may require specialty equipment, precisetolerances, and/or introduce process variability which increases themanufacturing cost of the jaw members.

SUMMARY

As used herein, the term “distal” refers to the portion that is beingdescribed which is closest to a patient, while the term “proximal”refers to the portion that is being described which is farthest from apatient. Further, to the extent consistent, any of the aspects describedherein may be used in conjunction with any or all of the other aspectsdescribed herein.

A method of manufacturing a jaw member of a surgical forceps inaccordance with the present disclosure includes forming a jaw frameincluding a distal jaw support. The method also includes forming anelectrically-conductive plate defining an aperture having a firstdiameter, forming a stop member including a body having a seconddiameter smaller than the first diameter and a shoulder having a thirddiameter greater than the first diameter. The method also includesinserting the stop member into the aperture such that the body extendsthrough the aperture and the shoulder abuts a portion of theelectrically-conductive plate surrounding the aperture, and overmoldingan outer housing about at least a portion of the jaw frame,electrically-conductive plate, and stop member to secure the jaw frame,electrically-conductive plate, and stop member to one another.

In one aspect of the present disclosure, the method further includespositioning an insulative spacer on the distal jaw support.

In another aspect the present disclosure, the electrically-conductiveplate is formed via stamping.

In another aspect of the present disclosure, forming the stop memberincludes forming a body portion of the stop member having a height suchthat the body portion of the stop member extends from atissue-contacting surface of the electrically-conductive plate adistance of between about 0.001 inches and about 0.006 inches.

In still another aspect of the present disclosure, positioning theinsulative spacer on the distal jaw support includes overmolding theinsulative spacer on the distal jaw support.

In yet another aspect of the present disclosure, the method furtherincludes positioning the electrically-conductive plate and the stopmember located therein on the insulative spacer and the jaw frame.

In another aspect of the present disclosure, the method further includesforming an outer housing about a portion of the jaw frame, theinsulative spacer, and the electrically-conductive plate such that thejaw frame, the insulative spacer, the electrically-conductive plate, andthe stop member located therein are secured in an assembled condition.

In still yet another aspect of the present disclosure, forming theelectrically-conductive plate includes deforming theelectrically-conductive plate to form a fill-aperture configured tolocate a portion of the outer housing.

In another aspect of the present disclosure, forming theelectrically-conductive plate includes deforming theelectrically-conductive plate such that the electrically-conductiveplate includes a thickness, wherein the difference between the height ofthe body portion of the stop member and the thickness of theelectrically-conductive plate is between about 0.001 inches and about0.006 inches.

In yet another aspect of the present disclosure, forming the stop memberincludes forming the stop member from a heat-resistant ceramic, whereinthe stop member is machined from a ceramic rod or slug.

In still another aspect of the present disclosure, forming the stopmember includes forming the stop member from a heat-resistant ceramic,wherein the stop member is injection molded.

According to aspects of the present disclosure, a method ofmanufacturing a jaw member of a surgical forceps includes stamping ablank to form an electrically-conductive plate including an aperturedefining a first diameter and at least one leg defining a fill-aperture.The method also includes machining a stop member including a body havinga second diameter smaller than the first diameter and a shoulder havinga third diameter greater than the first diameter of the aperture. Themethod also includes inserting the stop member into the aperture suchthat the body extends through the aperture and the shoulder abuts aportion of the electrically-conductive plate surrounding the aperture,and overmolding an outer housing about a portion of theelectrically-conductive plate and the stop member such that theelectrically-conductive plate and the stop member are secured to oneanother in an assembled condition.

In an aspect of the present disclosure, the method further includesinserting the stop member into the aperture of theelectrically-conductive plate such that the stop member extends from atissue-contacting surface of the electrically-conductive plate adistance of between about 0.001 inches and about 0.006 inches.

In another aspect of the present disclosure, machining the stop memberincludes deforming a ceramic rod or slug.

In still another aspect of the present disclosure, the method furtherincludes forming a jaw frame having a distal jaw support and overmoldingan insulative spacer onto the distal jaw support such that the jaw frameis electrically-isolated from the electrically-conductive plate.

In yet another aspect of the present disclosure, overmolding the outerhousing includes filling the fill-aperture of theelectrically-conductive plate with a portion of the outer housing.

BRIEF DESCRIPTION OF THE DRAWINGS

Various aspects and features of the present disclosure described hereinwith reference to the drawings wherein:

FIG. 1 is a perspective view of a surgical instrument provided inaccordance with the present disclosure with jaw members of the endeffector assembly of the surgical instrument disposed in a spaced-apartposition;

FIG. 2 is a longitudinal, cross-sectional view taken along section line“2-2” of FIG. 1;

FIG. 3 is a perspective view of the end effector assembly of thesurgical instrument of FIG. 1 including the jaw members disposed in thespaced-apart position;

FIG. 4 is a perspective view of the end effector assembly of thesurgical instrument of FIG. 1 including the jaw members disposed in theapproximated position;

FIG. 5 is a side, perspective view of the distal end of the surgicalinstrument of FIG. 1 with the jaw members disposed in the spaced-apartposition;

FIG. 6 is a side, perspective view of one of the jaw members of thesurgical instrument of FIG. 1 with a portion thereof removed;

FIG. 7A is a longitudinal, cross-sectional view taken along section line“7A-7A” of FIG. 6 including a jaw frame and an insulative spacerdisposed thereon;

FIG. 7B is a schematic view of a blank for forming anelectrically-conductive plate of the jaw member of FIG. 6;

FIG. 7C is a schematic view of forming the electrically-conductive platehaving an aperture and a stop member of the jaw member of FIG. 6;

FIG. 7D is a schematic view of the electrically-conductive plate havingthe aperture and the stop member of the jaw member of FIG. 6 disposedtherein; and

FIG. 7E is a schematic view of the electrically-conductive plate, thestop member, and the insulative spacer of the jaw member of FIG. 6 in anassembled condition.

DETAILED DESCRIPTION

Referring generally to FIGS. 1 and 2, a surgical instrument provided inaccordance with the present disclosure is shown generally identified byreference numeral 10. Instrument 10, as described below, is configuredfor grasping, treating, and/or dissecting tissue and may find particularapplicability for use in performing tonsillectomy and/or adenoidectomyprocedures, although use of instrument 10 in various other surgicalprocedures is also contemplated and within the scope of the presentdisclosure.

With reference to FIGS. 1-4, instrument 10 generally includes a housing20, a handle assembly 30, a trigger assembly 70, a shaft 80, an endeffector assembly 100, a drive assembly 140, a knife assembly 170, andan energy activation assembly 190. Shaft 80 extends distally fromhousing 20 and supports end effector assembly 100 at distal end 82thereof. Drive assembly 140 operably couples handle assembly 30 with endeffector assembly 100 to enable selective manipulation of jaw members110, 120 of end effector assembly 100. Knife assembly 170 is operablycoupled with trigger assembly 70 to enable selective translation of aknife blade 174 of knife assembly 170 relative to end effector assembly100. Energy activation assembly 190 enables energy to be selectivelydelivered to end effector assembly 100.

Instrument 10 may also include an electrosurgical cable (not shown) thatconnects instrument 10 to a generator (not shown) or other suitablepower source, although instrument 10 may alternatively be configured asa battery-powered instrument. The electrosurgical cable includes leadwires, e.g., lead wires 107 (see FIG. 4), extending therethrough thathave sufficient length to extend through housing 20 and shaft 80 inorder to operably couple the generator, energy activation assembly 190,and end effector assembly 100 with one another to enable the selectivesupply of energy to electrically-conductive plates 112, 122 of jawmembers 110, 120 of end effector assembly 100, e.g., upon activation ofactivation switch 194 of energy activation assembly 190.

For a detailed description of instrument 10, reference may be made toU.S. patent application Ser. No. 14/719,422, filed May 22, 2015,entitled “SURGICAL INSTRUMENTS AND METHODS FOR PERFORMING TONSILLECTOMY,ADENOIDECTOMY, AND OTHER SURGICAL PROCEDURES,” the entire contents ofwhich are incorporated by reference herein. However, the aspects andfeatures of the present disclosure are equally applicable for use withother suitable surgical instruments.

With additional reference to FIGS. 5 and 6, as mentioned above, endeffector assembly 100 is operably supported at distal end 82 of shaft 80and includes opposing jaw members 110, 120 pivotably coupled to oneanother and movable relative to one another and shaft 80 between aspaced-apart position (see FIG. 3) and an approximated position (seeFIG. 4) for grasping tissue therebetween. Each jaw member 110, 120includes an electrically-conductive plate 112, 122, a jaw frame 113,123, an insulative spacer 115 (only insulative spacer 115 of jaw member120 is shown, see FIGS. 7A and 7E), and an outer housing 118, 128, eachof which is detailed below.

Although only the features of jaw member 110 or jaw member 120 aredescribed below and/or illustrated in the figures, it is noted that jawmembers 110, 120 defines mirror-image configurations of one another(unless specifically contradicted herein) and, thus, any descriptionand/or illustration of one jaw member 110, 120 applies similarly to theother jaw member 110, 120.

Jaw frames 113, 123 of jaw members 110, 120 each include a pair ofspaced-apart proximal flanges 113 a, 123 a and a distal jaw support 113b, 123 b. Proximal flanges 113 a of jaw member 110 are spaced-apartfurther than proximal flanges 123 a of jaw member 120 so as to allowproximal flanges 123 a of jaw member 120 to be positioned betweenproximal flanges 113 a of jaw member 110 during assembly. Further, theproximal flanges 113 a, 123 a of each pair define aligned pivotapertures 114 a, 124 a and aligned cam slots 114 b, 124 b.

With brief reference to FIGS. 2 and 3, jaw members 110, 120 arepivotably coupled to one another and to shaft 80 via a pivot pin 103such that jaw members 110, 120 are laterally movable, e.g., along thelarger width dimension of shaft 80, between the spaced-apart andapproximated positions. The cam slots 114 b of proximal flanges 113 a ofjaw member 110 are oppositely angled relative to the cam slots 124 b ofproximal flanges 123 a of jaw member 120. A camming pin 105 of endeffector assembly 100 is configured for insertion through each cam slot114 b, 124 b as well as a cam-pin aperture (not shown) of the drive bar(not shown) of drive assembly 140 to operably couple drive assembly 140with jaw members 110, 120 such that translation of the drive bar ofdrive assembly 140 relative to jaw members 110, 120 pivots jaw members110, 120 about pivot pin 103 and relative to one another and shaft 80between the spaced-apart and approximated positions.

Distal jaw support 123 b of jaw frame 123 of jaw member 120 extendsdistally from proximal flange 123 a and defines a generally “L-shaped”configuration. Distal jaw support 123 b is configured to supportelectrically-conductive plate 122, insulative spacer 115 (see FIG. 7A),and outer housing 128 of jaw member 120 thereon. However, distal jawsupport 123 b does not extend distally the entire length of jaw member120. Rather, distal jaw support 123 b defines a length of about 50% toabout 75% of the lengths of electrically-conductive plate 122,insulative spacer 115, and outer housing 128 such that about 25% toabout 50% of the lengths of these components extend distally beyonddistal jaw support 123 b.

The electrically-conductive plate 112, 122 of each jaw member 110, 120defines a generally planar tissue-contacting surface 112 a, 122 a, anelongated slot 112 b, 122 b extending through the respectivetissue-contacting surface 112 a, 122 a, and a pair of legs 122 c (onlylegs 122 c of jaw member 120 are shown) extending downwardly from eachside of the respective tissue-contacting surface 112 a, 122 b.

Tissue-contacting surface 112 a of electrically-conductive plate 112 ofjaw member 110 and/or tissue-contacting surface 122 a ofelectrically-conductive plate 122 of jaw member 120 may further includea stop member 126 operably associated therewith. For illustrativepurposes, only one stop member 126 is shown in connection with jawmember 120. However, it is contemplated that jaw member 110 and/or jawmember 120 may include a plurality of stop members 126 at variousdifferent positions. Stop members 126 are configured to maintain aminimum clearance or gap distance “G” (see FIG. 4) between jaw members110, 120 within a specified range, typically about 0.001″ to about0.006″, although other ranges, depending upon a particular purpose, arealso contemplated.

Outer housings 118, 128 partially enclose respective jaw members 110,120 with the exception of a portion of the distal jaw support 113 b, 123b thereof and the tissue-contacting surface 112 a, 122 a thereof, whichremain exposed. As will be detailed below, outer housings 118, 128 areconfigured to secure the components of each jaw member 110, 120 in anassembled condition. Outer housings 118, 128 define lengths extendingalong the sides of respective jaw members 110, 120 and thicknesses thatdecrease in the proximal-to-distal direction along the lengths thereof.

With additional reference to FIGS. 7A-7E, the configuration andmanufacture jaw members 110, 120 is detailed in accordance with thepresent disclosure. However, since jaw members 110, 120 definemirror-image configurations of one another, and thus includesubstantially similar methods of manufacture, only the configuration andmanufacture of jaw member 120 is described to avoid repetition.

As noted above, jaw member 120 includes a jaw frame 123 configured tosupport insulative spacer 115 and electrically-conductive plate 122.Referring now to FIG. 7A, jaw frame 123 is formed via stamping and madefrom stainless steel, although other manufacturing processes and/ormaterials for forming jaw frame 123 are also contemplated. Insulativespacer 115 of jaw member 120 is formed from an electrically-insulativematerial and is positioned on distal jaw support 123 b toelectrically-isolate electrically-conductive plate 122 and distal jawsupport 123 b from one another. Insulative spacer 115 is overmolded ontodistal jaw support 123 b, although outer manufacturing processes arealso contemplated.

Referring now to FIGS. 7B and 7C, electrically-conductive plate 122 ofjaw member 120 is formed via stamping a blank “B” made from any suitabletemperature-resistant, electrically conductive material, such as, forexample, stainless steel, although other manufacturing processes and/ormaterials for forming electrically-conductive plate 122 are alsocontemplated. Blank “B” is provided and stamped to formelectrically-conductive plate 122 having generally planartissue-contacting surface 122 a, elongated slot 122 b (see FIG. 6), anda legs 122 c, as noted above. Once formed, electrically-conductive plate122 defines a thickness “T” between tissue-contacting surface 122 a anda bottom surface 122 e thereof.

During the stamping process, prior thereto, or after stamping,electrically-conductive plate 122 is punched such that an aperture 122 dextends entirely through tissue-contacting surface 122 a, thickness “T,”and bottom surface 122 e of electrically-conductive plate 122.Additionally, one or more fill-apertures 122 f (see also FIG. 6) areformed on legs 122 c of electrically-conductive plate 122.

Aperture 122 d of electrically-conductive plate 122 is configured tolocate stop member 126 therein, and as such, defines a shapecorresponding to a shape of at least a portion of stop member 126. Forexample, in some embodiments, stop member 126 has a generallycylindrical configuration and, thus, aperture 122 d has a correspondingcircular shape. However, other configurations, such as, for example,square, rectangular, oval, and the like, are also contemplated.

Referring now to FIGS. 7C and 7D, stop member 126 is constructedseparately from electrically-conductive plate 122. As noted above, stopmember 126 is configured to create a minimum clearance or gap distance“G” between jaw members 110, 120, typically within a specified range ofabout 0.001″ to about 0.006″. Given these tight tolerances, it iscontemplated that constructing stop member 126 separately fromelectrically-conductive plate 122, prior to inserting stop member 126into aperture 122 d of electrically-conductive plate 122, will reducethe variability in the manufacturing process, eliminate the need forprecision equipment for forming stop member 126 on or withelectrically-conductive plate 122, and ensure that the extension of stopmember 126 through aperture 122 d of electrically-conductive plate 122will fall within the specified range of about 0.001″ to about 0.006″.

Stop member 126 is constructed from heat-resistant ceramic and is formedvia machining ceramic rods or slugs or through an injection moldingprocess. Alternatively, it is contemplated that stop member 126 may beconstructed from other non-conductive materials, such as, for example, ahigh-strength thermosetting polymeric material and may be formed viaother suitable manufacturing processes.

Stop member 126 is formed to include a body portion 126 a and a shoulderportion 126 b. Body portion 126 a of stop member 126 has a diameter “D1”that is smaller than a diameter “D2” of aperture 122 d ofelectrically-conductive plate 122 such that body portion 126 a of stopmember 126 may be inserted therethrough. However, in order to preventstop member 126 from passing entirely through aperture 122 d, shoulderportion 126 b of stop member 126 has a diameter “D3” that is larger thandiameter “D2” of aperture 122 d, such that shoulder portion 126 b abutsthe portion of bottom surface 122 e of electrically-conductive plate 122that surrounds aperture 122 d. Further, stop member 126 is formed suchthat body portion 126 a of stop member 126 has a height “H,” wherein thedifference between height “H” of body portion 126 a and thickness “T” ofelectrically-conductive plate 122 is between about 0.001″ to about0.006″ so as to define a minimum gap distance “G” (FIG. 4) in thatrange. Alternatively, where jaw member 110 (FIGS. 3-4) includes anopposing stop member 126, the difference in height “H” of body portion126 a and thickness “T” of electrically-conductive plate 122 may be halfof that noted above, such that the opposing stop members 126 cooperateto define a minimum gap distance “G” (FIG. 4) in the above-noted range.Other suitable ranges are also contemplated.

After stop member 126 is inserted into aperture 122 d ofelectrically-conductive plate 122, the combination is positioned oninsulative spacer 115, as shown in FIG. 7E. Outer housing 128 is thenformed about jaw member 120 via an overmolding process, such that outerhousing 128 partially encloses jaw frame 123 (FIG. 7A),electrically-conductive plate 122, and insulative spacer 115 of jawmember 120 and secures these components in position relative to oneanother. During the overmolding process, the plurality of fill-apertures122 f (see also FIG. 6) on legs 122 c of electrically-conductive plate122 of jaw member 120 are filled with the overmolded material formingouter housing 128 to enhance the securement of the components of jawmember 120 in an assembled condition.

The various embodiments disclosed herein may also be configured to workwith robotic surgical systems and what is commonly referred to as“Telesurgery.” Such systems employ various robotic elements to assistthe surgeon and allow remote operation (or partial remote operation) ofsurgical instrumentation. Various robotic arms, gears, cams, pulleys,electric and mechanical motors, etc. may be employed for this purposeand may be designed with a robotic surgical system to assist the surgeonduring the course of an operation or treatment. Such robotic systems mayinclude remotely steerable systems, automatically flexible surgicalsystems, remotely flexible surgical systems, remotely articulatingsurgical systems, wireless surgical systems, modular or selectivelyconfigurable remotely operated surgical systems, etc.

The robotic surgical systems may be employed with one or more consolesthat are next to the operating theater or located in a remote location.In this instance, one team of surgeons or nurses may prep the patientfor surgery and configure the robotic surgical system with one or moreof the instruments disclosed herein while another surgeon (or group ofsurgeons) remotely control the instruments via the robotic surgicalsystem. As can be appreciated, a highly skilled surgeon may performmultiple operations in multiple locations without leaving his/her remoteconsole which can be both economically advantageous and a benefit to thepatient or a series of patients.

The robotic arms of the surgical system are typically coupled to a pairof master handles by a controller. The handles can be moved by thesurgeon to produce a corresponding movement of the working ends of anytype of surgical instrument (e.g., end effectors, graspers, knifes,scissors, etc.) which may complement the use of one or more of theembodiments described herein. The movement of the master handles may bescaled so that the working ends have a corresponding movement that isdifferent, smaller or larger, than the movement performed by theoperating hands of the surgeon. The scale factor or gearing ratio may beadjustable so that the operator can control the resolution of theworking ends of the surgical instrument(s).

The master handles may include various sensors to provide feedback tothe surgeon relating to various tissue parameters or conditions, e.g.,tissue resistance due to manipulation, cutting or otherwise treating,pressure by the instrument onto the tissue, tissue temperature, tissueimpedance, etc. As can be appreciated, such sensors provide the surgeonwith enhanced tactile feedback simulating actual operating conditions.The master handles may also include a variety of different actuators fordelicate tissue manipulation or treatment further enhancing thesurgeon's ability to mimic actual operating conditions.

From the foregoing and with reference to the various figure drawings,those skilled in the art will appreciate that certain modifications canalso be made to the present disclosure without departing from the scopeof the same. While several embodiments of the disclosure have been shownin the drawings, it is not intended that the disclosure be limitedthereto, as it is intended that the disclosure be as broad in scope asthe art will allow and that the specification be read likewise.Therefore, the above description should not be construed as limiting,but merely as exemplifications of particular embodiments. Those skilledin the art will envision other modifications within the scope and spiritof the claims appended hereto.

What is claimed is:
 1. A method of manufacturing a jaw member of asurgical forceps, comprising: forming a jaw frame of the jaw member, thejaw frame including a distal jaw support; forming anelectrically-conductive plate defining an aperture having a firstdiameter; forming a stop member including a body having a seconddiameter smaller than the first diameter and a shoulder having a thirddiameter greater than the first diameter; inserting the stop member intothe aperture such that the body extends through the aperture and theshoulder abuts a portion of the electrically-conductive platesurrounding the aperture; and overmolding an outer housing about atleast a portion of the jaw frame, electrically-conductive plate, andstop member to secure the jaw frame, electrically-conductive plate, andstop member to one another to form the jaw member.
 2. The methodaccording to claim 1, further comprising: positioning an insulativespacer on the distal jaw support.
 3. The method according to claim 2,further comprising: positioning the electrically-conductive plate andthe stop member located therein on the insulative spacer and the jawframe.
 4. The method according to claim 3, further comprising: formingan outer housing about a portion of the jaw frame, the insulativespacer, and the electrically-conductive plate such that the jaw frame,the insulative spacer, the electrically-conductive plate, and the stopmember located therein are secured in an assembled condition.
 5. Themethod according to claim 4, wherein forming the electrically-conductiveplate includes deforming the electrically-conductive plate to form afill-aperture configured to locate a portion of the outer housing. 6.The method according to claim 1, wherein forming the stop memberincludes forming a body portion of the stop member having a height suchthat the body portion of the stop member extends from atissue-contacting surface of the electrically-conductive plate adistance of between about 0.001 inches and about 0.006 inches.
 7. Themethod according to claim 6, wherein forming the electrically-conductiveplate includes deforming the electrically-conductive plate such that theelectrically-conductive plate includes a thickness, wherein thedifference between the height of the body portion of the stop member andthe thickness of the electrically-conductive plate is between about0.001 inches and about 0.006 inches.
 8. The method according to claim 1,wherein forming the electrically-conductive plate includes forming theelectrically-conductive plate via stamping.
 9. The method according toclaim 1, wherein positioning the insulative spacer on the distal jawsupport includes overmolding the insulative spacer on the distal jawsupport.
 10. The method according to claim 1, wherein forming the stopmember includes forming the stop member from a heat-resistant ceramic,wherein the stop member is machined from a ceramic rod or slug.
 11. Themethod according to claim 1, wherein forming the stop member includesforming the stop member from a heat-resistant ceramic, wherein the stopmember is injection molded.